101601-5931 ZEXEL INJECTION-PUMP ASSEMBLY Calibration Data 1016015931 220007513b

Information Cross number Calibration Data Calibration Data Ex

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Information injection-pump assembly

ZEXEL 101601-5931 1016015931

HINO 220007513B 220007513b

Service parts 101601-5931 INJECTION-PUMP ASSEMBLY:

1. _

2. FUEL INJECTION PUMP 101060-6030

3. GOVERNOR 105931-9190

4. SUPPLY PUMP 105210-5210

5. AUTOM. ADVANCE MECHANIS 105672-5130

6. COUPLING PLATE 105662-1310

7. COUPLING PLATE

8. _

9. _

10. NOZZLE AND HOLDER ASSY 105101-6593

11. Nozzle and Holder 23600-2373A

12. Open Pre:MPa(Kqf/cm2) 19.6{200}

13. NOZZLE-HOLDER 105030-3431

14. NOZZLE 105015-9200

15. NOZZLE SET

Include in #1:

101601-5931 as INJECTION-PUMP ASSEMBLY

Include in #2:

104139-4022 as _

Cross reference number

ZEXEL 101601-5931 1016015931

HINO 220007513B 220007513b

Zexel num

Bosch num

Firm num

Name

101601-5931
101601-5932

220007513B HINO

INJECTION-PUMP ASSEMBLY
J08C * K

Calibration Data:

Adjustment conditions

Test oil
1404 Test oil ISO4113 or {SAEJ967d}

Test oil temperature degC 40 40 45

Nozzle and nozzle holder 105780-8140

Bosch type code EF8511/9A

Nozzle 105780-0000

Bosch type code DN12SD12T

Nozzle holder 105780-2080

Bosch type code EF8511/9

Opening pressure MPa 17.2

Opening pressure kgf/cm2 175

Injection pipe
Outer diameter - inner diameter - length (mm) mm 6-2-600

Overflow valve 131424-8320

Overflow valve opening pressure kPa 108 88 128

Overflow valve opening pressure kgf/cm2 1.1 0.9 1.3

Tester oil delivery pressure kPa 157 157 157

Tester oil delivery pressure kgf/cm2 1.6 1.6 1.6

Direction of rotation (viewed from drive side)
Left L

Injection timing adjustment

Direction of rotation (viewed from drive side)
Left L

Injection order 1-4-2-6- 3-5

Pre-stroke mm 4.3 4.27 4.33

Beginning of injection position
Governor side NO.1

Difference between angles 1
Cal 1-4 deg. 60 59.75 60.25

Difference between angles 2
Cyl.1-2 deg. 120 119.75 120.25

Difference between angles 3
Cal 1-6 deg. 180 179.75 180.25

Difference between angles 4
Cal 1-3 deg. 240 239.75 240.25

Difference between angles 5
Cal 1-5 deg. 300 299.75 300.25

Injection quantity adjustment

Adjusting point -

Rack position 12.4

Pump speed r/min 950 950 950

Average injection quantity mm3/st. 85.1 83.5 86.7

Max. variation between cylinders % 0 -3.5 3.5

Basic *

Fixing the rack *

Standard for adjustment of the maximum variation between cylinders *

Injection quantity adjustment_02

Adjusting point H

Rack position 9.5+-0.5

Pump speed r/min 250 250 250

Each cylinder's injection qty mm3/st. 15.4 14.4 16.4

Fixing the rack *

Standard for adjustment of the maximum variation between cylinders *

Injection quantity adjustment_03

Adjusting point A

Rack position R1(12.4)

Pump speed r/min 950 950 950

Average injection quantity mm3/st. 85.1 84.1 86.1

Basic *

Fixing the lever *

Injection quantity adjustment_04

Adjusting point B

Rack position R1+0.6

Pump speed r/min 1450 1450 1450

Average injection quantity mm3/st. 89.3 85.3 93.3

Fixing the lever *

Injection quantity adjustment_05

Adjusting point C

Rack position R1-0.55

Pump speed r/min 580 580 580

Average injection quantity mm3/st. 73.6 69.6 77.6

Fixing the lever *

Injection quantity adjustment_06

Adjusting point I

Rack position -

Pump speed r/min 100 100 100

Average injection quantity mm3/st. 136 136 146

Fixing the lever *

Rack limit *

Timer adjustment

Pump speed r/min 950--

Advance angle deg. 0 0 0

Load 1/4

Remarks
Start

Timer adjustment_02

Pump speed r/min 900

Advance angle deg. 0.3

Load 1/4

Timer adjustment_03

Pump speed r/min (1000)

Advance angle deg. 1.5 1.2 1.8

Load 4/4

Remarks
Measure the actual speed.

Timer adjustment_04

Pump speed r/min 1240+50

Advance angle deg. 1.5 1.2 1.8

Load 4/4

Timer adjustment_05

Pump speed r/min 1450-50

Advance angle deg. 5 4.7 5.3

Load 4/4

Remarks
Finish

Test data Ex:

Governor adjustment

N:Pump speed R:Rack position (mm) (1)Torque cam stamping: T1 (2)Tolerance for racks not indicated: +-0.05mm. (3)RACK LIMIT
----------
T1=G90
----------

Speed control lever angle

F:Full speed I:Idle (1)Use the hole at R = aa (2)Stopper bolt set position 'H'
----------
aa=41mm
----------
a=34deg+-5deg b=(45.5deg)+-3deg

Stop lever angle

N:Pump normal S:Stop the pump. (1)Use the hole at R = aa (2)Set the stopper bolt at speed = bb and rack position = cc (non-injection rack position). Confirm non-injection. (3)After setting the stopper bolt, confirm non-injection at speed dd. Rack position = non-injection rack position (actual measurement)
----------
aa=38mm bb=1450r/min cc=7-0.5mm dd=250r/min
----------
a=28deg+-5deg b=26deg+-5deg